Process for the preparation of intermediates

ABSTRACT

The present invention provides a process for the production of intermediate compounds of formula (I), wherein the substituents are as defined herein. The process comprises reacting a substituted aniline with aqueous HX, followed by removal of water by azeotropic distillation and diazotization and pyrolysis with an organic nitrite at elevated temperatures in the absence of a copper catalyst. Alternatively, gaseous HX can be used to substitute aqueous HX in the process. Consequently, a step of water removal by azeotropic distillation can be eliminated. The intermediate compounds of formula I are suitable as intermediates in the preparation of herbicidally active 3-hydroxy-4-aryl-5-oxopyrazoline derivatives.

The present invention relates to an improved process for the preparation of substituted benzene derivatives useful as intermediates in the production of herbicidally active substituted 3-hydroxy-4-aryl-5-oxopyrazoline derivatives.

3-Hydroxy-4-aryl-5-oxopyrazolines having herbicidal action and the preparation thereof are described, for example, in WO 92/16510, EP-A-0 508 126, WO 95/01971, WO 96/21652, WO 96/25395, WO 97/02243 and in WO 99/47525, the contents of which are all incorporated by reference.

It has now been discovered that substituted benzene derivatives, key intermediates in the process for preparing herbicidally active substituted 3-hydroxy-4-aryl-5-oxopyrazoline derivatives, can be prepared in high yield with a considerable cost advantage over known processes.

The present invention accordingly relates to preparation of a compound of formula I

wherein

R₀ is, each independently of any other, halogen, C₁-C₆alkyl, C₂-C₆alkenyl, C₂-C₆alkynyl, C₁-C₆haloalkyl, cyano-C₁-C₆alkyl, C₂-C₆haloalkenyl, cyano-C₂-C₆alkenyl, C₂-C₆haloalkynyl, cyano-C₂-C₆alkynyl, hydroxy, hydroxy-C₁-C₆alkyl, C₁-C₆alkoxy, nitro, amino, C₁-C₆alkylamino, di(C₁-C₆alkyl)amino, C₁-C₆alkylcarbonylamino, C₁-C₆alkylsulfonylamino, C₁-C₆alkylaminosulfonyl, C₁-C₆alkylcarbonyl, C₁-C₆alkylcarbonyl-C₁-C₆alkyl, C₁-C₆alkoxycarbonyl-C₁-C₆alkyl, C₁-C₆alkylcarbonyl-C₂-C₆alkenyl, C₁-C₆alkoxycarbonyl, C₁-C₆alkoxycarbonyl-C₂-C₆alkenyl, C₁-C₆alkylcarbonyl-C₂-C₆alkynyl, C₁-C₆alkoxycarbonyl-C₂-C₆alkynyl, cyano, carboxyl, phenyl or an aromatic ring that contains 1 or 2 hetero atoms selected from the group consisting of nitrogen, oxygen and sulfur, wherein the latter two aromatic rings may be substituted by C₁-C₃alkyl, C₁-C₃haloalkyl, C₁-C₃alkoxy, C₁-C₃haloalkoxy, halogen, cyano or by nitro; or

R₀, together with the adjacent substituents R₁, R₂ and R₃, forms a saturated or unsaturated C₃-C₆hydrocarbon bridge that may be interrupted by 1 or 2 hetero atoms selected from the group consisting of nitrogen, oxygen and sulfur and/or substituted by C₁-C₄alkyl;

R₁, R₂ and R₃ are, each independently of the others, hydrogen, halogen, C₁-C₆alkyl, C₂-C₆alkenyl, C₂-C₆alkynyl, C₃-C₆cycloalkyl, C₁-C₆haloalkyl, C₂-C₆haloalkenyl, C₁-C₆alkoxy-carbonyl-C₂-C₆alkenyl, C₁-C₆alkylcarbonyl-C₂-C₆alkenyl, cyano-C₂-C₆alkenyl, nitro-C₂-C₆alkenyl, C₂-C₆haloalkynyl, C₁-C₆alkoxycarbonyl-C₂-C₆alkynyl, C₁-C₆alkylcarbonyl-C₂-C₆alkynyl, cyano-C₂-C₆alkynyl, nitro-C₂-C₆alkynyl, C₃-C₆halocycloalkyl, hydroxy-C₁-C₆alkyl, C₁-C₆alkoxy-C₁-C₆alkyl, C₁-C₆alkylthio-C₁-C₆alkyl, cyano, C₁-C₄alkylcarbonyl, C₁-C₆alkoxycarbonyl, hydroxy, C₁-C₁₀alkoxy, C₃-C₆alkenyloxy, C₃-C₆alkynyloxy, C₁-C₆haloalkoxy, C₃-C₆haloalkenyloxy, C₁-C₆alkoxy-C₁-C₆alkoxy, mercapto, C₁-C₆alkylthio, C₁-C₆haloalkylthio, C₁-C₆alkylsulfinyl, C₁-C₆alkylsulfonyl, nitro, amino, C₁-C₆alkylamino, di(C₁-C₆alkyl)amino or phenoxy in which the phenyl ring may be substituted by C₁-C₃alkyl, C₁-C₃haloalkyl, C₁-C₃alkoxy, C₁-C₃haloalkoxy, halogen, cyano or by nitro;

R₂ also may be phenyl, naphthyl or a 5- or 6-membered aromatic ring that may contain 1 or 2 hetero atoms selected from the group consisting of nitrogen, oxygen and sulfur, wherein the phenyl ring, the naphthyl ring system and the 5- or 6-membered aromatic ring may be substituted by halogen, C₃-C₈cycloalkyl, hydroxy, mercapto, amino, cyano, nitro or by formyl; and/or

the phenyl ring, the naphthyl ring system and the 5- or 6-membered aromatic ring may be substituted by C₁-C₆alkyl, C₁-C₆alkoxy, hydroxy-C₁-C₆alkyl, C₁-C₆alkoxy-C₁-C₆alkyl, C₁-C₆alkoxy-C₁-C₆alkoxy, C₁-C₆alkylcarbonyl, C₁-C₆alkylthio, C₁-C₆alkylsulfinyl, C₁-C₆alkylsulfonyl, mono-C₁-C₆alkylamino, di(C₁-C₆alkyl)amino, C₁-C₆alkylcarbonylamino, C₁-C₆alkylcarbonyl-(C₁-C₆alkyl)amino, C₂-C₆alkenyl, C₃-C₆alkenyloxy, hydroxy-C₃-C₆alkenyl, C₁-C₆alkoxy-C₂-C₆alkenyl, C₁-C₆alkoxy-C₃-C₆alkenyloxy, C₂-C₆alkenylcarbonyl, C₂-C₆alkenylthio, C₂-C₆alkenyl-sulfinyl, C₂-C₆alkenylsulfonyl, mono- or di-(C₂-C₆alkenyl)amino, C₁-C₆alkyl(C₃-C₆alkenyl)-amino, C₂-C₆alkenylcarbonylamino, C₂-C₆alkenylcarbonyl(C₁-C₆alkyl)amino, C₂-C₆alkynyl, C₃-C₆alkynyloxy, hydroxy-C₃-C₆alkynyl, C₁-C₆alkoxy-C₃-C₆alkynyl, C₁-C₆alkoxy-C₄-C₆alkynyloxy, C₂-C₆alkynylcarbonyl, C₂-C₆alkynylthio, C₂-C₆alkynylsulfinyl, C₂-C₆alkynylsulfonyl, mono- or di-(C₃-C₆alkynyl)amino, C₁-C₆alkyl(C₃-C₆alkynyl)amino, C₂-C₆alkynylcarbonylamino or by C₂-C₆alkynylcarbonyl(C₁-C₆alkyl)amino; and/or

the phenyl ring, the naphthyl ring system and the 5- or 6-membered aromatic ring may be substituted by halo-substituted C₁-C₆alkyl, C₁-C₆alkoxy, hydroxy-C₁-C₆alkyl, C₁-C₆alkoxy-C₁-C₆alkyl, C₁-C₆alkoxy-C₁-C₆alkoxy, C₁-C₆alkylcarbonyl, C₁-C₆alkylthio, C₁-C₆alkylsulfinyl, C₁-C₆alkylsulfonyl, mono-C₁-C₆alkylamino, di(C₁-C₆alkyl)amino, C₁-C₆alkylcarbonylamino, C₁-C₆alkylcarbonyl(C₁-C₆alkyl)amino, C₂-C₆alkenyl, C₃-C₆alkenyloxy, hydroxy-C₃-C₆alkenyl, C₁-C₆alkoxy-C₂-C₆alkenyl, C₁-C₆alkoxy-C₃-C₆alkenyloxy, C₂-C₆alkenylcarbonyl, C₂-C₆alkenylthio, C₂-C₆alkenylsulfinyl, C₂-C₆alkenylsulfonyl, mono- or di-(C₂-C₆alkenyl)amino, C₁-C₆-alkyl(C₃-C₆alkenyl)amino, C₂-C₆alkenylcarbonylamino, C₂-C₆alkenylcarbonyl(C₁-C₆alkyl)amino, C₂-C₆alkynyl, C₃-C₆alkynyloxy, hydroxy-C₃-C₆alkynyl, C₁-C₆alkoxy-C₃-C₆alkynyl, C₁-C₆alkoxy-C₄-C₆alkynyloxy, C₂-C₆alkynylcarbonyl, C₂-C₆alkynylthio, C₂-C₆alkynylsulfinyl, C₂-C₆alkynylsulfonyl, mono- or di-(C₃-C₆alkynyl)amino, C₁-C₆alkyl(C₃-C₆alkynyl)amino, C₂-C₆alkynylcarbonylamino or C₂-C₆alkynylcarbonyl(C₁-C₆alkyl)amino; and/or

the phenyl ring, the naphthyl ring system and the 5- or 6-membered aromatic ring may be substituted by a radical of formula COOR₅₀, CONR₅₁, SO₂NR₅₃R₅₄ or SO₂OR₅₅, wherein R₅₀, R₅₁, R₅₂, R₅₃, R₅₄ and R₅₅ are, each independently of the others, C₁-C₆alkyl, C₂-C₆alkenyl or C₃-C₆alkynyl or halo-, hydroxy-, alkoxy-, mercapto-, amino-, cyano-, nitro-, alkylthio-, alkylsulfinyl- or alkylsulfonyl-substituted C₁-C₆alkyl, C₂-C₆alkenyl or C₃-C₆alkynyl;

X is halogen; and

n is 0, 1 or 2.

In the above definitions, halogen is to be understood as fluorine, chlorine, bromine or iodine, preferably fluorine, chlorine or bromine, and most preferably chlorine and bromine. The alkyl groups occurring in the substituent definitions are, for example, methyl, ethyl, n-propyl, isopropyl, n-butyl, sec-butyl, isobutyl or tert-butyl, and the pentyl, hexyl, heptyl, octyl, nonyl, decyl, undecyl and dodecyl isomers.

Haloalkyl groups preferably have a chain length of from 1 to 6 carbon atoms. Haloalkyl is, for example, fluoromethyl, difluoromethyl, difluorochloromethyl, trifluoromethyl, chloromethyl, dichloromethyl, dichlorofluoromethyl, trichloromethyl, 2,2,2-trifluoroethyl, 2-fluoroethyl, 2-chloroethyl, 2,2-difluoroethyl, 2,2-dichloroethyl, 2,2,2-trichloroethyl or pentafluoroethyl, preferably trichloromethyl, difluorochloromethyl, difluoromethyl, trifluoromethyl or dichlorofluoromethyl.

Alkoxy groups preferably have a chain length of from 1 to 6 carbon atoms. Alkoxy is, for example, methoxy, ethoxy, n-propoxy, isopropoxy, n-butoxy, isobutoxy, sec-butoxy, tert-butoxy, or a pentyloxy or hexyloxy isomer, preferably methoxy, ethoxy or n-propoxy.

Haloalkoxy is, for example, fluoromethoxy, difluoromethoxy, trifluoromethoxy, 2,2,2-trifluoroethoxy, 1,1,2,2-tetrafluoroethoxy, 2-fluoroethoxy, 2-chloroethoxy or 2,2,2-trichloroethoxy.

There may be mentioned as examples of alkenyl radicals vinyl, allyl, methallyl, 1-methylvinyl, but-2-en-1-yl, pentenyl and 2-hexenyl; preferably alkenyl radicals having a chain length of from 3 to 6 carbon atoms.

There may be mentioned as examples of alkynyl radicals ethynyl, propargyl, 1-methyl-propargyl, 3-butynyl, but-2-yn-1-yl, 2-methylbut-3-yn-2-yl, but-3-yn-2-yl, 1-pentynyl, pent-4-yn-1-yl and 2-hexynyl; preferably alkynyl radicals having a chain length of from 3 to 6 carbon atoms.

Suitable haloalkenyl radicals include alkenyl groups substituted one or more times by halogen, halogen being in particular bromine or iodine and especially fluorine or chlorine, for example 2- and 3-fluoropropenyl, 2- and 3-chloropropenyl, 2- and 3-bromopropenyl, 2,2-difluoro-1-methylvinyl, 2,3,3-trifluoropropenyl, 3,3,3-trifluoropropenyl, 2,3,3-trichloropropenyl, 4,4,4-trifluorobut-2-en-1-yl and 4,4,4-trichlorobut-2-en-1-yl. Preferred alkenyl radicals substituted once, twice or three times by halogen are those having a chain length of from 3 to 6 carbon atoms. The alkenyl groups may be substituted by halogen at saturated or unsaturated carbon atoms.

Alkoxyalkyl groups have preferably from 1 to 6 carbon atoms. Alkoxyalkyl is, for example, methoxymethyl, methoxyethyl, ethoxymethyl, ethoxyethyl, n-propoxymethyl, n-propoxyethyl, isopropoxymethyl or isopropoxyethyl.

Haloalkoxy is, for example, fluoromethoxy, difluoromethoxy, trifluoromethoxy, 2,2,2-trifluoroethoxy, 1,1,2,2-tetrafluoroethoxy, 2-fluoroethoxy, 2-chloroethoxy or 2,2,2-trichloroethoxy.

Alkenyloxy is, for example, allyloxy, methallyloxy or but-2-en-1-yloxy.

Suitable haloalkenyloxy groups include alkenyloxy groups substituted one or more times by halogen, halogen being in particular bromine or iodine and especially fluorine or chlorine, for example 2- and 3-fluoropropenyloxy, 2- and 3-chloropropenyloxy, 2- and 3-bromopropenyloxy, 2,3,3-trifluoropropenyloxy, 2,3,3-trichloropropenyloxy, 4,4,4-trifluorobut-2-en-1-yloxy and 4,4,4-trichlorobut-2-en-1-yloxy.

Alkynyloxy is, for example, propargyloxy or 1-methylpropargyloxy.

Suitable cycloalkyl substituents contain from 3 to 8 carbon atoms and are, for example, cyclopropyl, cyclobutyl, cyclopentyl, cyclohexyl, cycloheptyl or cyclooctyl. They may be substituted one or more times by halogen, preferably fluorine, chlorine or bromine.

Alkylcarbonyl is especially acetyl or propionyl.

Alkoxycarbonyl is, for example, methoxycarbonyl, ethoxycarbonyl, n-propoxycarbonyl, isopropoxycarbonyl or a butoxycarbonyl, pentyloxycarbonyl or hexyloxycarbonyl isomer, preferably methoxycarbonyl or ethoxycarbonyl.

Alkylthio groups preferably have a chain length of from 1 to 6 carbon atoms. Alkylthio is, for example, methylthio, ethylthio, propylthio, butylthio, pentylthio or hexylthio, or a branched isomer thereof, but is preferably methylthio or ethylthio.

Haloalkylthio is, for example, 2,2,2-trifluoroethylthio or 2,2,2-trichloroethylthio.

Alkylsulfinyl is, for example, methylsulfinyl, ethylsulfinyl, n-propylsulfinyl, isopropylsulfinyl, n-butylsulfinyl, isobutylsulfinyl, sec-butylsulfinyl or tert-butylsulfinyl, preferably methylsulfinyl or ethylsulfinyl.

Alkylsulfonyl is, for example, methylsulfonyl, ethylsulfonyl, n-propylsulfonyl, isopropylsulfonyl, n-butylsulfonyl, isobutylsulfonyl, sec-butylsulfonyl or tert-butylsulfonyl, preferably methylsulfonyl or ethylsulfonyl.

Alkylamino is, for example, methylamino, ethylamino, n-propylamino, isopropylamino or a butyl-, pentyl- or hexyl-amine isomer.

Dialkylamino is, for example, dimethylamino, methylethylamino, diethylamino, n-propylmethylamino, dibutylamino or diisopropylamino.

Alkylthioalkyl is, for example, methylthiomethyl, methylthioethyl, ethylthiomethyl, ethylthioethyl, n-propylthiomethyl, n-propylthioethyl, isopropylthiomethyl or isopropylthioethyl.

Phenyl and naphthyl in the definition of R₂ and phenoxy in the definition of R₁, R₂ and R₃ may be in substituted form, in which case the substituents may, as desired, be in the ortho-, meta- and/or para-position and, in the case of the naphthyl ring system, in addition in the 5-, 6-, 7- and/or 8-position.

Examples of suitable 5- or 6-membered aromatic rings that contain 1 or 2 hetero atoms selected from the group consisting of nitrogen, oxygen and sulfur in the definition of R₀ and R₂ are pyrrolidyl, pyridyl, pyrimidyl, triazinyl, thiazolyl, triazolyl, thiadiazolyl, imidazolyl, oxazolyl, isoxazolyl, pyrazinyl, furyl, thienyl, pyrazolyl, benzoxazolyl, benzothiazolyl, quinoxalyl, indolyl and quinolyl. These heteroaromatic radicals may, in addition, be substituted.

Meanings corresponding to those given hereinbefore can also be ascribed to substituents in composite definitions, such as, for example, alkoxy-alkoxy, alkyl-sulfonylamino, alkylaminosulfonyl, phenyl-alkyl, naphthyl-alkyl and heteroaryl-alkyl.

In the definitions for alkylcarbonyl and alkoxycarbonyl, the carbon atom of the carbonyl is not included in the upper and lower limits given for the number of carbons in each particular case.

Preference is given to compounds of formula I wherein n and X are as defined for formula I; R₀ is, each independently of any other, halogen, C₁-C₆alkyl, C₁-C₆haloalkyl, hydroxy, C₁-C₆alkoxy, nitro, amino, C₁-C₆alkylamino, di(C₁-C₆alkyl)amino, C₁-C₆alkylcarbonylamino, C₁-C₆alkylsulfonylamino, C₁-C₆alkylaminosulfonyl, C₁-C₄alkylcarbonyl, C₁-C₆alkoxycarbonyl or carboxyl; and R₁, R₂ and R₃ are, each independently of the others, hydrogen, halogen, C₁-C₆alkyl, C₂-C₆alkenyl, C₂-C₆alkynyl, C₃-C₆cycloalkyl, C₁-C₆-haloalkyl, C₂-C₆haloalkenyl, C₂-C₆haloalkynyl, C₃-C₆halocycloalkyl, C₁-C₆alkoxy-C₁-C₆alkyl, C₁-C₆alkylthio-C₁-C₆alkyl, cyano, C₁-C₄alkylcarbonyl, C₁-C₆alkoxycarbonyl, hydroxy, C₁-C₁₀alkoxy, C₃-C₆alkenyloxy, C₃-C₆alkynyloxy, C₁-C₆haloalkoxy, C₃-C₆haloalkenyloxy, C₁-C₆alkoxy-C₁-C₆alkoxy, mercapto, C₁-C₆alkylthio, C₁-C₆haloalkylthio, C₁-C₆alkylsulfinyl, C₁-C₆alkylsulfonyl, nitro, amino, C₁-C₄alkylamino or di(C₁-C₄alkyl)amino.

Preference is given also to compounds of formula I wherein R₁, R₂ and R₃ are, each independently of the others, hydrogen, halogen, C₁-C₆alkyl, C₁-C₄haloalkyl, C₂-C₄alkenyl, C₂-C₄haloalkenyl, C₂-C₄alkynyl, C₃-C₆cycloalkyl, C₁-C₄alkylcarbonyl, C₁-C₆alkoxycarbonyl, hydroxy, C₁-C₄alkoxy, C₃- or C₄-alkenyloxy, C₃- or C₄-alkynyloxy, C₁-C₄haloalkoxy, nitro or amino.

Preference is given also to compounds of formula I wherein R₁, R₂ and R₃ are C₁-C₄alkyl and X is halogen.

Likewise preferred are compounds of formula I wherein n is 0.

Of those, special preference is given to compounds of formula I wherein R₁ and R₃ are C₂-C₄alkyl, R₂ is C₁-C₃alkyl, and X is Cl or Br. Especially preferred compounds of formula I are those wherein R₁ and R₃ are ethyl or propyl, R₂ is methyl or ethyl, and X is chloro or bromo. Even more especially preferred compounds of formula I are those wherein n is 0, R₁ and R₃ are ethyl, R₂ is methyl, and X is chloro or bromo.

Preparation of substituted benzenes according to formula I by classical Sandmeyer reactions are known in the art. For example, WO00078712 describes a classical Sandmeyer reaction for the production of 1-bromo-2,6-diethyl-4-methylbenzene.

It has now been found, surprisingly, that a variation of the classical Sandmeyer reaction, wherein gaseous or aqueous acid is employed in non-aqueous Sandmeyer conditions, produces 1-halo-2,6-diethyl-4-methylbenzene in greater yields. More particularly, in a classic Sandmeyer reaction, the diazonium salt is added into a cuprous halide solution, tending to minimize formation of phenol and hydrocarbon coupling reactions. In most cases, the reaction takes place at 0-20° C. and requires the use of a molar amount of cuprous halide to promote the pyrolysis of diazonium salt. In the process of the present invention, metal halide or onium halide is used in the reaction to provide a source of additional solubilized halide ion, further minimizing the phenol formation. Additionally, in case of aqueous acid being employed, water removal by azeotropic distillation helps to minimize the phenol formation, thus improving yields. The diazonium salt is generated in situ, i.e., the diazotization and pyrolysis are carried out simultaneously at elevated temperatures, and the reaction proceeds without the use of copper.

The present process is distinguished by:

-   -   a) use of gaseous or aqueous acid in non-aqueous Sandmeyer         reactions;     -   b) use of metal halide or onium halide in the reaction to         provide a source of additional solubilized halide ion, further         minimizing the phenol formation;     -   c) in case that aqueous acid is used, water removal by         azeotropic distillation helps to minimize phenol formation, thus         improving yield of the substituted benzene product;     -   d) in situ formation of the diazonium salt by simultaneous         diazotization and pyrolysis at elevated temperatures;     -   e) absence of copper reagents necessary for classical Sandmeyer         reactions;     -   f) reduced phenol by-products make it possible to purify the         substituted benzene products by vacuum distillation;     -   g) ability to recover and recycle process chemicals such as         solvent and by-product alcohol in the process.

The present preparation process is therefore suitable especially for the cost-effective, large-scale preparation of substituted benzene derivatives of formula I.

The process according to the invention for the preparation of compounds of formula I comprises reacting a compound of formula II

wherein R₀, R₁, R₂, R₃ and n are as defined for formula I, with aqueous acid in non-aqueous Sandmeyer reactions in the absence of copper. Water removal by azeotropic distillation minimizes the phenol formation and therefore improves the yield of the compound of formula I. Alternatively, gaseous acid can be used to replace aqueous acid in the reactions. Consequently, a step of water removal by azeotropic distillation can be eliminated.

The preparation of compounds of formula I is illustrated in the following Reaction Scheme 1.

According to Reaction Scheme 1, the compounds of formula I are obtained from the aniline compounds of formula II by reacting the aniline compounds of formula II, in a first reaction step, with aqueous HX acid in a suitable organic solvent to form the aniline.HX salt, followed by water removal via azeotropic distillation. Alternatively, anhydrous aniline.HX salt can be formed directly by the reaction of aniline compound of formula II and gaseous HX acid in a suitable organic solvent. The first step of the process of the present invention may include the addition of a suitable metal halide or onium halides (PTC), to further improve the yield. In the second step of the process of the present invention, addition of an organic nitrite forms the diazonium salt in situ by simultaneously carrying out the diazotization and pyrolysis steps at elevated temperature ranges. Unlike classical Sandmeyer reactions, the process of the present invention proceeds in the absence of copper and produces compounds of formula I in high yield.

Examples of suitable organic solvents for the reaction of compounds of formula II with gaseous or aqueous HX (Step 1 in Reaction Scheme 1) include, for example and not for limitation, dibromomethane, 1,2-dibromoethane, 1,2-dichloroethane, dodecane, heptane, methylcyclohexane, toluene, xylene, chlorobenzene, dichlorobenzene, and mesitylene. o-Dichlorobenzene is a preferred organic solvent.

Examples of suitable metal halides or onium halides useful in Step 1 in Reaction Scheme 1 include, but are not limited to, sodium bromide, potassium bromide, sodium chloride, tetrabutylammonium bromide, tetrabutylphosphonium bromide, and methyltributylammonium chloride.

Examples of suitable organic nitrites useful in Step 2 in Reaction Scheme 1 include, but are not limited to, alkyl nitrites, such as isoamyl nitrite, n-pentyl nitrite, n-butyl nitrite, and t-butyl nitrite.

Reaction conditions proceed at elevated temperatures. In Step 1 of Reaction Scheme 1, the formation of the aniline.HX salt is carried out at reaction temperatures of about 40° to about 55° C., and the reaction thereof with the organic nitrite in the absence of copper or copper reagents (Step 2 in Reaction Scheme 1) is carried out at reaction temperatures of from about 50° to about 55° C. Temperatures during the azeotropic distillation step in Step 1 may reach up to 110° C., preferably about 100° C.

If the starting materials employed are not enantiomerically pure, the compounds of formula I obtained in the above-described process are generally in the form of racemates or diastereoisomeric mixtures which, if desired, can be separated on the basis of their physico-chemical properties according to known methods, such as, for example, fractional crystallisation following salt formation with optically pure bases, acids or metal complexes, or by chromatographic procedures, such as, for example, high-pressure liquid chromatography (HPLC) on acetyl cellulose.

Depending on the substituents R₀ to R₃, the compounds of formula I may be in the form of geometric and/or optical isomers and isomeric mixtures (atropisomers) or as tautomers and tautomeric mixtures.

The Examples that follow further illustrate the invention without limiting it.

PREPARATION EXAMPLES Example P1 Preparation of 1-bromo-2,6-diethyl-4-methylbromobenzene With Gaseous Hydrogen Bromide

Gaseous hydrogen bromide (1.05 equiv.) is fed into a mixture of 2,6-diethyl-4-methylaniline (1.00 equiv.) and sodium bromide (0.10 equiv.) in o-dichlorobenzene. The resulting salt suspension is cooled to 50° C. Isoamyl nitrite (1.05 equiv.) and additional gaseous hydrogen bromide (0.3 equiv.) are fed subsurface simultaneously at 50-55° C. over a 2-hour period to afford 1-bromo-2,6-diethyl-4-methylbenzene as a yellow to light brown solution. The reaction mass is neutralized with 25% caustic solution (ca. 0.3 equiv.). The bottom aqueous phase is separated off. Isoamyl alcohol and o-dichlorobenzene are sequentially stripped off to produce the crude 2,6-diethyl-4-methylbromobenzene material with an assay of 90% and an isolated yield of 87-90%. The product can be further purified by vacuum distillation at 95° C./5 mmHg to give an assay of 97-99%.

Example P2 Preparation of 1-bromo-2,6-diethyl-4-methybenzene With Aqueous Hydrobromic Acid

48% aqueous hydrobromic acid (1.05 equiv.) is fed into a mixture of diethylmethylaniline (1.00 equiv.) and sodium bromide (0.10 equiv.) in o-dichlorobenzene. Water is then azeotroped off under vacuum. The resulting salt suspension is cooled to 50° C. n-Pentyl nitrite (1.05 equiv.) is fed subsurface at 50-55° C. over 2-hour period to afford 1-bromo-2,6-diethyl-4-methylbenzene as a yellow to light brown solution. The bottom aqueous phase is separated off. The organic phase is washed with 10% sodium carbonate solution (0.15 equiv.). n-Pentanol and o-dichlorobenzene are sequentially stripped off to produce the crude 1-bromo-2,6-diethyl-4-methylbenzene material with an assay of 90% and an isolated yield of 83-85%. The product can be further purified by vacuum distillation at 95° C./5 mmHg to give an assay of 97-99%.

Example P3 Preparation of 1-chloro-2,6-diethyl-4-methylbenzene With Gaseous Hydrogen Chloride

Gaseous hydrogen chloride (1.05 equiv.) is fed into a solution of 2,6-diethyl-4-methylaniline (1.00 equiv.) in o-dichlorobenzene, allowing the pot temperature to rise to 70° C. The resulting salt suspension is cooled to 45° C. Isoamyl nitrite (1.05 equiv.) and additional gaseous hydrogen chloride (0.50 equiv.) are fed subsurface simultaneously at 45-50° C. over a 2-hour period to afford 1-chloro-2,6-diethyl-4-methylbenzene in 90-93% yield. 20% sodium hydroxide (0.50 equiv.) is added to adjust the pH to 10-12. The bottom aqueous phase is separated off. Isoamyl alcohol and o-dichlorobenzene are stripped off to produce the crude 1-chloro-2,6-diethyl-4-methylbenzene material. The product can be further purified by vacuum distillation at 85° C./5 mmHg to give an assay of 97-99%.

Example P4 Preparation of 1-chloro-2,6-diethyl-4-methylbenzene With Aqueous Hydrogen Chloride

37% aqueous hydrochloric acid can be used to replace gaseous hydrogen chloride in the process of example P3. An additional step of azeotropic distillation is needed to remove water after 2,6-diethyl-4-methylaniline.HCl salt formation. A drying agent such as CaCl₂ or CaSO₄ is optionally added in the diazotization step to achieve good yield. 

1. A process for the preparation of a compound of formula I

wherein R₀ is, each independently of any other, halogen, C₁-C₆alkyl, C₂-C₆alkenyl, C₂-C₆alkynyl, C₁-C₆haloalkyl, cyano-C₁-C₆alkyl, C₂-C₆haloalkenyl, cyano-C₂-C₆alkenyl, C₂-C₆haloalkynyl, cyano-C₂-C₆alkynyl, hydroxy, hydroxy-C₁-C₆alkyl, C₁-C₆alkoxy, nitro, amino, C₁-C₆alkylamino, di(C₁-C₆alkyl)amino, C₁-C₆alkylcarbonylamino, C₁-C₆alkylsulfonylamino, C₁-C₆alkylaminosulfonyl, C₁-C₆alkylcarbonyl, C₁-C₆alkylcarbonyl-C₁-C₆alkyl, C₁-C₆alkoxycarbonyl-C₁-C₆alkyl, C₁-C₆alkylcarbonyl-C₂-C₆alkenyl, C₁-C₆alkoxycarbonyl, C₁-C₆alkoxycarbonyl-C₂-C₆alkenyl, C₁-C₆alkylcarbonyl-C₂-C₆alkynyl, C₁-C₆alkoxycarbonyl-C₂-C₆alkynyl, cyano, carboxyl, phenyl or an aromatic ring that contains 1 or 2 hetero atoms selected from the group consisting of nitrogen, oxygen and sulfur, wherein the latter two aromatic rings may be substituted by C₁-C₃alkyl, C₁-C₃haloalkyl, C₁-C₃alkoxy, C₁-C₃haloalkoxy, halogen, cyano or by nitro; or R₀, together with the adjacent substituents R₁, R₂ and R₃, forms a saturated or unsaturated C₃-C₆hydrocarbon bridge that may be interrupted by 1 or 2 hetero atoms selected from the group consisting of nitrogen, oxygen and sulfur and/or substituted by C₁-C₄alkyl; R₁, R₂ and R₃ are, each independently of the others, hydrogen, halogen, C₁-C₆alkyl, C₂-C₆alkenyl, C₂-C₆alkynyl, C₃-C₆cycloalkyl, C₁-C₆haloalkyl, C₂-C₆haloalkenyl, C₁-C₆alkoxy-carbonyl-C₂-C₆alkenyl, C₁-C₆alkylcarbonyl-C₂-C₆alkenyl, cyano-C₂-C₆alkenyl, nitro-C₂-C₆alkenyl, C₂-C₆haloalkynyl, C₁-C₆alkoxycarbonyl-C₂-C₆alkynyl, C₁-C₆alkylcarbonyl-C₂-C₆alkynyl, cyano-C₂-C₆alkynyl, nitro-C₂-C₆alkynyl, C₃-C₆halocycloalkyl, hydroxy-C₁-C₆alkyl, C₁-C₆alkoxy-C₁-C₆alkyl, C₁-C₆alkylthio-C₁-C₆alkyl, cyano, C₁-C₄alkylcarbonyl, C₁-C₆alkoxycarbonyl, hydroxy, C₁-C₁₀alkoxy, C₃-C₆alkenyloxy, C₃-C₆alkynyloxy, C₁-C₆haloalkoxy, C₃-C₆haloalkenyloxy, C₁-C₆alkoxy-C₁-C₆alkoxy, mercapto, C₁-C₆alkylthio, C₁-C₆haloalkylthio, C₁-C₆alkylsulfinyl, C₁-C₆alkylsulfonyl, nitro, amino, C₁-C₆alkylamino, di(C₁-C₆alkyl)amino or phenoxy in which the phenyl ring may be substituted by C₁-C₃alkyl, C₁-C₃haloalkyl, C₁-C₃alkoxy, C₁-C₃haloalkoxy, halogen, cyano or by nitro; R₂ also may be phenyl, naphthyl or a 5- or 6-membered aromatic ring that may contain 1 or 2 hetero atoms selected from the group consisting of nitrogen, oxygen and sulfur, wherein the phenyl ring, the naphthyl ring system and the 5- or 6-membered aromatic ring may be substituted by halogen, C₃-C₈cycloalkyl, hydroxy, mercapto, amino, cyano, nitro or by formyl; and/or the phenyl ring, the naphthyl ring system and the 5- or 6-membered aromatic ring may be substituted by C₁-C₆alkyl, C₁-C₆alkoxy, hydroxy-C₁-C₆alkyl, C₁-C₆alkoxy-C₁-C₆alkyl, C₁-C₆alkoxy-C₁-C₆alkoxy, C₁-C₆alkylcarbonyl, C₁-C₆alkylthio, C₁-C₆alkylsulfinyl, C₁-C₆alkylsulfonyl, mono-C₁-C₆alkylamino, di(C₁-C₆alkyl)amino, C₁-C₆alkylcarbonylamino, C₁-C₆alkylcarbonyl-(C₁-C₆alkyl)amino, C₂-C₆alkenyl, C₃-C₆alkenyloxy, hydroxy-C₃-C₆alkenyl, C₁-C₆alkoxy-C₂-C₆alkenyl, C₁-C₆alkoxy-C₃-C₆alkenyloxy, C₂-C₆alkenylcarbonyl, C₂-C₆alkenylthio, C₂-C₆alkenyl-sulfinyl, C₂-C₆alkenylsulfonyl, mono- or di-(C₂-C₆alkenyl)amino, C₁-C₆alkyl(C₃-C₆alkenyl)-amino, C₂-C₆alkenylcarbonylamino, C₂-C₆alkenylcarbonyl(C₁-C₆alkyl)amino, C₂-C₆alkynyl, C₃-C₆alkynyloxy, hydroxy-C₃-C₆alkynyl, C₁-C₆alkoxy-C₃-C₆alkynyl, C₁-C₆alkoxy-C₄-C₆alkynyloxy, C₂-C₆alkynylcarbonyl, C₂-C₆alkynylthio, C₂-C₆alkynylsulfinyl, C₂-C₆alkynylsulfonyl, mono- or di-(C₃-C₆alkynyl)amino, C₁-C₆alkyl(C₃-C₆alkynyl)amino, C₂-C₆alkynylcarbonylamino or by C₂-C₆alkynylcarbonyl(C₁-C₆alkyl)amino; and/or the phenyl ring, the naphthyl ring system and the 5- or 6-membered aromatic ring may be substituted by halo-substituted C₁-C₆alkyl, C₁-C₆alkoxy, hydroxy-C₁-C₆alkyl, C₁-C₆alkoxy-C₁-C₆alkyl, C₁-C₆alkoxy-C₁-C₆alkoxy, C₁-C₆alkylcarbonyl, C₁-C₆alkylthio, C₁-C₆alkylsulfinyl, C₁-C₆alkylsulfonyl, mono-C₁-C₆alkylamino, di(C₁-C₆alkyl)amino, C₁-C₆alkylcarbonylamino, C₁-C₆alkylcarbonyl(C₁-C₆alkyl)amino, C₂-C₆alkenyl, C₃-C₆alkenyloxy, hydroxy-C₃-C₆alkenyl, C₁-C₆alkoxy-C₂-C₆alkenyl, C₁-C₆alkoxy-C₃-C₆alkenyloxy, C₂-C₆alkenylcarbonyl, C₂-C₆alkenylthio, C₂-C₆alkenylsulfinyl, C₂-C₆alkenylsulfonyl, mono- or di-(C₂-C₆alkenyl)amino, C₁-C₆-alkyl(C₃-C₆alkenyl)amino, C₂-C₆alkenylcarbonylamino, C₂-C₆alkenylcarbonyl(C₁-C₆alkyl)amino, C₂-C₆alkynyl, C₃-C₆alkynyloxy, hydroxy-C₃-C₆alkynyl, C₁-C₆alkoxy-C₃-C₆alkynyl, C₁-C₆alkoxy-C₄-C₆alkynyloxy, C₂-C₆alkynylcarbonyl, C₂-C₆alkynylthio, C₂-C₆alkynylsulfinyl, C₂-C₆alkynylsulfonyl, mono- or di-(C₃-C₆alkynyl)amino, C₁-C₆alkyl(C₃-C₆alkynyl)amino, C₂-C₆alkynylcarbonylamino or C₂-C₆alkynylcarbonyl(C₁-C₆alkyl)amino; and/or the phenyl ring, the naphthyl ring system and the 5- or 6-membered aromatic ring may be substituted by a radical of formula COOR₅₀, CONR₅₁, SO₂NR₅₃R₅₄ or SO₂OR₅₅, wherein R₅₀, R₅₁, R₅₂, R₅₃, R₅₄ and R₅₅ are, each independently of the others, C₁-C₆alkyl, C₂-C₆alkenyl or C₃-C₆alkynyl or halo-, hydroxy-, alkoxy-, mercapto-, amino-, cyano-, nitro-, alkylthio-, alkylsulfinyl- or alkylsulfonyl-substituted C₁-C₆alkyl, C₂-C₆alkenyl or C₃-C₆alkynyl; X is halogen; and n is 0, 1 or 2; which comprises (a) reacting a compound of formula (II)

with gaseous or aqueous HX in an organic solvent, wherein X is as defined above for formula (I); (b) removing water by azeotropic distillation in case that aqueous HX is used; and (c) adding an organic nitrite, wherein the process takes place in the absence of copper.
 2. The process according to claim 1, wherein X is chloro or bromo.
 3. The process according to claim 2, wherein R₁, R₂ and R₃ are independently C₁-C₆ alkyl and n is
 0. 4. The process according to claim 3, R₁ and R₃ are ethyl, and R₂ is methyl.
 5. The process according to claim 4, wherein the organic solvent is selected from the group consisting of dibromomethane, 1,2-dibromoethane, 1,2-dichloroethane, dodecane, heptane, methylcyclohexane, toluene, o-xylene, chlorobenzene, o-dichlorobenzene, and mesitylene.
 6. The process according to claim 4, wherein the organic nitrite is selected from the group consisting of isoamyl nitrite, n-pentyl nitrite, n-butyl nitrite, and t-butyl nitrite.
 7. The process according to claim 4, wherein step (a) further comprises adding a metal halide or onium halide, wherein halide is X and is as defined for formula (I).
 8. The process according to claim 4, wherein the azeotropic distillation of step (b) takes place at a temperature between about 50-110° C.
 9. The process according to claim 4, wherein the temperature of step (c) is between 40-100° C.
 10. The process according to claim 4, further comprising removing water by-product and residual acid by neutralization with an inorganic base and phase separation.
 11. The process according to claim 10, further comprising distilling off and recycling of by-product alcohol and organic solvent.
 12. The process according to claim 11, further comprising purifying the compound of formula (I) formed by the process by vacuum distillation.
 13. The process according to claim 1 to produce a compound of formula (I) wherein X is bromo, which comprises (a) reacting a compound of formula II

wherein n is 0, R₁ and R₃ are ethyl, and R₂ is methyl, with gaseous or aqueous HBr in o-dichlorobenzene; (b) removing water by azeotropic distillation at a vacuum pressure until the temperature reaches about 100° C. in the case that aqueous HBr is employed; and (c) adding n-pentyl nitrite at a temperature of about 45-55° C., wherein the process takes place in the absence of copper; (d) removing water by-product and residual acid by neutralization with an organic base selected from sodium hydroxide and sodium carbonate, followed by phase separation; (e) purifying the compound of formula (I) by vacuum distillation.
 14. The process according to claim 13, wherein sodium bromide is added to the reaction in (a).
 15. The process according to claim 1, to produce a compound of formula (I) wherein X is chloro, which comprises (a) reacting a compound of formula II

wherein n is 0, R₁ and R₃ are ethyl, and R₂ is methyl, with gaseous or aqueous HCl in o-dichlorobenzene; (b) removing water by azeotropic distillation at a vacuum pressure until the temperature reaches about 100° C. in case that aqueous HCl is employed; and (c) adding isoamyl nitrite at a temperature of about 44-50° C., wherein the process takes place in the absence of copper; (d) removing water by-product and residual acid by neutralization with an organic base selected from sodium hydroxide and sodium carbonate, followed by phase separation; (f) purifying the compound of formula (I) by vacuum distillation.
 16. The process according to claim 15, wherein sodium chloride is added to the reaction in (a). 